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PERFORMANCE

Performance & Heavy Duty

TransmissionParts

Contents
SmartShell HD Reaction Shell Kit 2
4L60-E Performance Pack3
Line Pressure Booster Kits 4

PERFORMANCE

Input Housing Shafts & Kits 56


Pinless Accumulator Piston Kits5
2nd & 4th Gear Servos7
Billet Forward Piston 8
Heavy-Duty 2-3 Shift Valve 8
Bushing Upgrades 8
Parts Listing 910
Sonnax Build Charts11

Sonnax.com
The #1 Site for Cutting-Edge
Transmission Solutions
Sonnax Products
Find information on thousands of
Sonnax parts quickly and easily
online. We offer a full range of
transmission, high performance
and torque converter products, plus
specialized drivetrain components.
Request a catalog if you want a
handy reference for the bench.

4L60/E

Heavy Duty &


Performance

Transmission Parts
Sonnax Transmission Upgrades
Meet the toughest Challenges
From cutting-edge speed & power for competitive
racing vehicles to extra durability for hard-working
utility trucks, trust Sonnax to deliver the absolute
BEST in transmission performance!
Become a Sonnax Insider!

Get the scoop on all the newest


Sonnax products & tech resources:

Technical Resources
Comprehensive instructions for
Sonnax parts are available on
our website any time you need
them. The popular Sonnax online
technical library also is a great
resource, with hundreds of articles
on everyday transmission issues
as well as unique rebuilding
challenges.

Where to Buy
Ready to order? Find out where
to purchase genuine Sonnax parts
from an online listing of authorized
Sonnax distributors in the U.S.
and other countries.

Contact Sonnax
(800) 843-2600 (802) 463-9722
info@sonnax.com
www.sonnax.com

Get your
gearhead on

Sonnax 4L60/E Performance & Heavy Duty Transmission Catalog Vol. 1

2013 Sonnax Industries, Inc.

Fix 4L60 sun


gear shell problems
with BRAINS,
not just brawn!

SmartShell

Heavy-Duty Reaction Shell Kit

The SmartShell is the


ULTIMATE SHELL for all
performance applications!

Save the
Planetary Bearing
In the OE sun gear shell, the thrust
load passes from the shell through
the sun gear, then overloads
the small captured planetary bearing.
To protect this bearing, the
SmartShell features a custom bearing
assembly and roller clutch race that
re-routes the thrust load directly to
the carrier, completely bypassing the
delicate bearing.

Stop Sun Gear


Shell Breakage
The SmartShell is a stronger shell
that avoids the weight found in
traditional, heavy-duty aftermarket
shells with some unique
improvements:
Slightly thicker shell than OE.

Get SMART About Sun Gear Shells


Many aftermarket replacements try to compensate with bigger, beefier
shells, but strengthening the shell alone does nothing to address the
equally common problem of a failed rear planet captured bearing.
Only the SmartShell can stop breakage AND protect the bearing.

Strong shell avoids the weight found in traditional,


heavy-duty aftermarket shells
Large bearing withstands max thrust loads
Custom bearing & roller clutch race STOP planetery
bearing failure

SmartShell Video at www.sonnax.com


Go inside the 4L60 sun gear shell to see the
source of common failures and learn how the
SmartShell stops them all.

The hub area is reinforced with


an electron-beam welded collar
and undergoes a final machining
process for precision alignment.
The shell splines and lugs are
heat-treated for outstanding
durability.

SmartShell HD Reaction Shell Kit


4L60, 4L60-E, 4L65-E, 4L70-E

Sun Gear Shell


Large Bearing
Custom Roller Clutch Race
Part No. 77749-02K
Patent no. 8,377,356

SmartShell Video Also On

Scan code with smartphone to watch video now!

Get your gearhead on www.sonnax.com


2

A MUST for any


heavy-duty vehicle and the
BEST foundation for high
performance racing.

Performance
Shifts on Demand
Get firmer shifting under load without
sacrificing low-speed drivability.
Its the ULTIMATE way to get an
impressive transmission that
responds to throttle and increased
load with quick, firm shifts.

Consistent
Calibration Results

The BEST Sonnax Parts


for Performance &
Heavy Duty Recalibration

4L60-E
Performance
Pack

Select kit components are precision


engineered to recalibrate pressures
and shift accumulation.

The best working performance


units we have done,
and thats not from me,
but my customers.

Repair & Prevent Damage


High-quality, innovative and durable
Sonnax parts target commonly worn
areas in the transmission and prevent
future damage.

B. Bastedo
Advanced Transmission Care
Mooresville, N.C.

Performance Pack
4L60-E (94-Later), 4L65-E, 4L70-E
Part No.

HP-4L60E-01

The parts listed here may be protected by one


of these patent numbers: 6,619,323 & 6,899,211.

Pump Parts
Pressure Regulator Spring
Boost Valve, .490"
Pump Slide Spring

Accumulator Parts
1-2 Pinless Piston Kit
1-2 Piston Springs
1-2 Waved Spring

Servo Parts
4th Servo Return Spring
Servo Cushion Spring
Servo Piston
D-Ring Kit

Sonnax 4L60/E Performance & Heavy Duty Transmission Catalog Vol. 1

Valve Body Parts


Forward Pinless
Accumulator Piston Kit
Accumulator Valve Shim
TCC Spring & Valve

Case Parts
3-4 Accumulator Piston Kit
3-4 Accumulator Spring
Servo Release
Check Valve

2013 Sonnax Industries, Inc.

The Sonnax progressive


boost valve will put a smile
on your customers face.
D. Stewart
Dan's Service Center
Cliff, N.M.

Simple, Affordable,
Drop-In Parts

Big Performance
without a Big Price Tag

No special tools or reaming required.

Line Pressure

Stronger PR Spring
Sonnax springs are about 10%
stronger than OE springs. Unlike
other, stronger aftermarket springs,
our springs wont overload the pump
at idle, produce harsh, low-speed
shifts or engagements.

Booster Kits

Larger Boost Valve


Assembly

Stronger PR
Valve Spring

The large ratio boost valve is


engineered for exceptional line rise
precision, intelligently controlling lowand high-end line pressure increases.

Large Ratio Boost


Valve Assembly

The SMART, affordable


& safe way to raise line pressure.
Sonnaxs unique combination of larger boost valves and stronger
springs results in normal engagements, normal light throttle shifts
and smooth coast-down shifts.
When pushed harder or driven aggressively, pressure increase
becomes progressively greater, ensuring that shifts are not too soft.

The Benefits of Progressive Pressure

Light

Low

Line Pressure High

Sonnax

Competitors

Sonnax

OE

ine

Competitors

re

Throttle

Anodized Aluminum Boost Assembly


Pressure Regulator Spring
O-Rings (2)

For Long, Early-Style Pumps


Part No. 4L60E-LB1
For Short, Late-Style Pumps
Part No. 4L60E-LB2

Competitors Kits with Stronger Springs


= Unresponsive, Steady (Linear) Increase

su

4L60-E Booster Kits 4L60-E, 4L65-E, 4L70-E

Patent No. 6,619,323

Sonnax Booster Kit Valves & Springs


= Responsive, Variable (Progressive) Increase

s
Pre

Sonnax booster kits deliver


all the BENEFITS of increased
line pressure without overloading
the pump at idle.

Patent No. 6,619,323

4L60 Booster Kit 4L60 (700-R4), 200-4R


Steel Boost Valve Assembly
Pressure Regulator Spring
O-Rings (2)
Part No. 700R4-LB1
Patent No. 6,619,323

Hard

Get your gearhead on www.sonnax.com


4

Input Drum Reinforcement Kit


4L60, 4L60-E, 4L65-E, 4L70-E

Reinforcement Sleeve
Overrun Piston w/ Seals
FWD Piston Outer & Inner Seals
Part No.

77733-01K

Input Drum
Reinforcement Kit
Chrome-moly steel sleeve
Reworked OE piston & O-ring
Sleeve design will not block
clutch feed oil

77733-11S
77733-12S

77733-10S

300mm & 298mm


Heavy Duty Input Shafts

300mm Heavy Duty Input Shafts


4L60-E, 4L65-E, 4L70-E

For Non-Reluctor Units


Part No. 77733-11S
For Reluctor Units
Part No. 77733-12S
298mm Heavy Duty Input Shaft
4L60, 4L60-E
Part No.

77733-10S

The perfect upgrades


for OE-strength input shafts.
High strength material for high-horsepower
street or strip applications
Chamfered feed holes and shot peening reduce
stress cracks and increase service life
Deep cryogenic treatment for extra toughness

Each accumulator kit includes:


Pinless Accumulator Piston
D-Ring & PTFE Seal
Steel Balls (2)

Pinless Accumulator Piston Kit


4L60, 4L60-E, 4L65-E, 4L70-E
Part No.

77998-03K

Patent No. 6,899,211

Fits 1-2 or 3-4 Bores

Replacement Seal Kit 77998-03SK

Pinless Forward
Accumulator Piston Kit
4L60-E, 4L65-E, 4L70-E

Pinless Accumulator
Piston Kits
Pinless design eliminates the
possibility of pin leakage; steel
balls plug existing pin bore
Dual seals stabilize & provide
a tight seal even after thousands
of cycles

77998-03K

Patent No. 6,899,211

Added length stabilizes piston


to prevent piston cocking

Replacement Seal Kit 77987-SK

Replacement seals also available

Part No.

77987-01K

77987-01K

Sonnax 4L60/E Performance & Heavy Duty Transmission Catalog Vol. 1

2013 Sonnax Industries, Inc.

The ULTIMATE
3-4 Clutch Pack

.165" Greater Capacity


Between Plates than
OE 7-Friction Setup

SOLUTION

Smart-Tech

Input Housing Kit

Although incremental improvements to aftermarket parts have


been made addressing 4L60-series 3-4 clutch problems, they
failed to keep pace with steadily increasing power levels of
modern performance engines...until now!
The Sonnax Smart-Tech tackles ALL the 3-4 clutch
issues of the 4L60 as no other housing has done before!

Key Smart-Tech Kit Components


4L60, 4L60-E, 4L65-E, 4L70-E

Limited 3-4 Clutch Capacity


Anchor (backing) plate works with redesigned apply
plate for more room and clutch options for eight or
nine frictions for increased torque capacity.

3-4 Clutch Anchor (Backing) Plate


Modified Input Housing
Input Drum Reinforcement Sleeve
Rear Stator Support Bushing
Overrun Piston
3-4 Clutch Apply Plate
3-4 Clutch Return Springs
Socket Head Cap Screws
Seals (5)
Part No.

6 Frictions

7 Frictions

4L60-E Late

4L65-E/4L70-E

8 Frictions

77733-06K

Patent pending

9 Frictions

Sonnax Smart-Tech

Smart-Tech kits
also come assembled
with input shaft!

3-4 Backing Plate Flexing & Distortion


Zero-flex, bolt-on anchor plate replaces
OE backing plate to eliminate clutch pack
distortion and uneven clamping pressure.

Smart-Tech Kit w/ Heavy Duty Input Shaft


300mm Shaft Kit for Non-Reluctor Units

77733-11K

Input Housing Fatigue Failure

Part No.

Treated housing is significantly


more resistant to fatigue failure.

300mm Shaft Kit for Reluctor Units

Aluminum Housing Breakage

298mm Shaft Kit

Steel input drum reinforcement sleeve


prevents breakage in the shaft/spline area.

3-4 Retaining Ring Blow-Out


Fifteen bolts secure anchor plate,
eliminating snap-ring and blow-out concerns.

Part No.

Part No.

Patent pending

77733-12K
77733-10K

Patent pending

Patent pending

The Smart-Tech requires 91-later 3-4


apply ring, 97-later ring gear and
96-earlier aluminum forward piston or
Sonnax billet forward piston 77764-01
(see pg. 8). It cannot be used with
stamped steel forward piston.

Get your gearhead on www.sonnax.com


6

Combine Sonnax 2nd


and 4th gear super hold servos
for unmatched holding power
and shift performance!

The ultimate
Servo Combination

Super Hold
Servos

77767K
77911-03K

More Apply Area

2nd Gear Super Hold Servo Kit

Easy to Install
No transmission removal is required.

Billet Aluminum
For super strength and durability.

2 Gear Super Hold Servo


nd

4L60, 4L60-E, 4L65-E, 4L70-E

Piston w/ D-Rings
Separator w/ D-Ring & O-Rings
Apply Pin w/ PTFE & O-Ring Seals
Part No.

77911-03K

Replacement Seal Kit 77911-03SK

4th Gear Super Hold Servo


4L60, 4L60-E, 4L65-E, 4L70-E

Servo w/ D-Ring

Steel Washer

The perfect upgrade for more


holding power without excessively harsh
upshifts and downshifts.
18% More apply area than the
Corvette servo (largest OE).
Maximizes holding power
in 2nd gear with more
positive 1-2 and 2-3 shifts.
Dual seals ensure positive
band apply/release and
eliminate cross leaks.
Apply pin has added seals to
reduce leakage of 3rd gear pressure.

4th Gear Super Hold


Dual Servo Kit

Part No. 77767K


Patent No. 5,944,627

40% More apply area.

Replacement Seal Kit 77767K-SK

D-ring seals for improved sealing.

Patented dual-piston design.

Sonnax 4L60/E Performance & Heavy Duty Transmission Catalog Vol. 1

2013 Sonnax Industries, Inc.

Customize transmission
performance with key parts
for more speed, strength
and durability!

Billet
Forward
Piston

Billet Forward Piston

eliminates breakage

caused by rough housings & high stress.

4L60, 4L60-E, 4L65-E, 4L70-E


Part No.

77764-01

This piston can be used by itself or with a variety of Sonnax input drum and housing reinforcement kits.
See pages 5 and 6 for details.

Heavy-Duty 2-3 Shift Valve


Drop-In replacement
Extends life of the forward clutch & input sprag

Heavy-Duty 2-3 Shift Valve


4L60, 4L60-E, 4L65-E, 4L70-E
Part No.

77754-41

This Sonnax valve applies the overrun clutch in


D3, 1st, 2nd and 3rd gears for added durability,
where the OE valve applies the overrun clutch only
in D3, 3rd gear. This valve also works well with
aftermarket electronic paddle shifters to allow full downshift
engine braking in 2nd while the shifter remains in the D3 position.

Bushing Upgrades

Rear Stator Support Bushing


The BEST option to
support the 20 lb. input
housing & improve reliability.
Better-fitting, drop-in upgrade
PTFE-coated

Rear Stator Support Bushing


4L60, 4L60-E, 4L65-E, 4L70-E
Part No.

77002BT-01

This bushing is included in Sonnax


Smart-Tech input housing kits.
See page 6 for details.

Wide Sun Gear Bushing


Stops oil Leakage
1.5X Wider than OE bushing
to maximize support for
sun gear & reaction shell

Wide Sun Gear Bushing


4L60, 4L60-E, 4L65-E, 4L70-E
Part No.

77010-01

Steel-backed bronze

Pump Bushing

Pump Bushing
4L60, 4L60-E, 4L65-E, 4L70-E

Drop-in replacement

Part No.

PTFE-coated

Also Upgrades 200-4R, 4L60 (700-4R) & 5L40-E units.

77005T

Get your gearhead on www.sonnax.com


8

Build the BEST Transmission

Sonnax specializes in a wide range of innovative, high-quality


parts for the very best everyday or performance rebuilds.

Part Name

Description

Tool
Required

4L70-E

4L65-E

4L60-E

4L60

Items listed in RED here should always be considered


for performance or heavy-duty applications.

Part No.

Valve Body Parts


TCC Regulator Valve Kit

Fits all years & EC3 units

Yes

77754-04K

TCC Regulator Valve Kit

Non-EC3 units, 97-earlier

Yes

77754-03K

Isolator Valve Kit

For worn isolator bore in unserviced VB


or for any factory-remanufactured VB

Yes

77754-ISO

60

Throttle Plunger Valve Kit

OE #93

77966-93K

60

Throttle Plunger Valve Kit

OE #94

77966-94K

Throttle Plunger Valve Kit

Prevents forced 4-3 kickdown


until 3/4 throttle

77966-94MK

60E

65E

70E

60E
60E

65E

70E

60

Oversized Throttle Valve

60
60E

65E

70E

3-2 Control Valve Spring

60E

65E

70E

3-4 Relay O-Ringed End Plug Kit

60E

65E

70E

4-3 Sequence Valve Kit

Yes

77754-23
77964-08K
Yes

60

60E

Accumulator Valve Train Kit

Heavy-weight vehicles

60

60E

Accumulator Valve Train Kit

Medium-weight vehicles

60E

65E

70E

Actuator Feed Limit Valve Kit

60E

65E

70E

3-4 Shift Valve Kit

Includes matched spring

77777L-K
Yes

77754-09K

Yes

77754-42K
77872-01

Throttle Valve

60

77964-04K
77777M-K

Shortened TV Link

60

77968

77968-02

60E

65E

70E

Forward & Reverse Abuse Bore Plug

Fits either location

77754-21

60E

65E

70E

Forward & Reverse Abuse Valve Kit

Improved design, fits either location

77754-35K

60E

65E

70E

AFL Valve End Plug

5/Bag

77754-39

TV Plunger Spring

5/Bag

77968-01K

Purple, 5/bag

74926

60

Case Parts
60

60E

65E

70E

1-2 or 3-4 Accumulator Spring

60

60E

65E

70E

3-4 Accumulator Sleeve Kit

77998-01K

60

60E

65E

70E

Servo Release Check Valve

77701-076

Oversized Accumulator Pin & Reamer Kit

77999-02K

60

Oversized Accumulator Pin Kit

60
65E

70E

Oversized Accumulator Pin & Reamer Kit

Includes 10 pins & reamer

60E

65E

70E

Oversized Accumulator Pin

Includes 4 pins only

60E

60

Yes

60E

77999
77754-02K

Yes

77754-01K

Shift Cable Mount Bracket

34913-01
77980-01K

60E

65E

70E

Wiring Harness Connector Bracket

60E

65E

70E

Accumulator Spring

Enhanced performance, 5/Bag

77704S

70E

Alto Extra Wide Intermediate Band

Regular red lining (street version)

77700-01

Servo Parts
60

60E

65E

60

60E

65E

70E

Alto Extra Wide Intermediate Band

Kevlar lining

77700-01K

60

60E

65E

70E

Extra Long Servo Pin Kit

Includes seals

77787-02K

60

60E

65E

70E

2nd Gear Corvette Ratio Servo Kit

Replacement seal kit available

77701-04K

Sonnax 4L60/E Performance & Heavy Duty Transmission Catalog Vol. 1

2013 Sonnax Industries, Inc.

Scan code with smartphone to browse all Sonnax 4L60-E parts online.

Tool
Required

4L70-E

4L65-E

4L60-E

4L60

Visit www.sonnax.com for the most


current product offerings, tech support,
distributor listings & more!

Part Name

Description

Part No.

Stator Support Shaft

300mm or 280mm, non-reluctor, 9904

77918S-1K

60E

Stator Support Shaft

298mm or 245mm, non-reluctor, 8204

77918S-K

60E

Stator Support Shaft

298mm Converter, reluctor, 04-later

77918S-08K

Pump Parts
60E
60

65E

70E

60E

65E

70E

Stator Support Shaft

280 or 300mm, reluctor, 04-later

77918S-09K

60E

65E

70E

TCC Apply Valve Kit

Aluminum with PTFE seal (PWM)

77805E-K
77805-K

60

60E

TCC Apply Valve Kit

Steel with PTFE seal (non-PWM)

60

60E

TCC Solenoid Snout Kit

96-Earlier

77942-01K

60

Oversized Pressure Regulator Valve

60

Reverse Boost Valve Kit

K77898

60

Reverse Boost Valve Kit

K77898A

60

60

Yes

60E

65E

70E

Pump Slide Pivot Pin

60E

65E

70E

Oversized Pressure Regulator Valve

60E

65E

70E

Stator Support Bushing Kit

For stator support shaft 77918S-K

77918SBK

Stator Front Bushing

Early

35007B

Stator Front Bushing

Late

35007A

60

5/Bag

77917-06

65797
Yes

77917-07

60

60E

65E

60

60E

65E

70E

Stator Rear Bushing

60

60E

65E

70E

Pump Vane

Koyo (OE)

1280

60

TV Boost Valve Kit

O-Ring Style, .500"

77917-500

60

TV Boost Valve Kit

Factory style, .500"

77917-04K

60

Elevated Pressure Regulator Spring

77002B

77917-08

60E

65E

70E

High Perf. Pressure Regulator Spring

60

60E

65E

70E

Pump Spring Spacer

10/Bag

77917-10
77917-RV

60

60E

65E

70E

Pump Slide Spring

5/Bag, replaces 2 OE springs

77722-01K

77763-01

Internal Transmission Parts


60

60E

65E

70E

3-4 Clutch Boost Spring

88-Later, 10/Bag
2.157" x .199" Black, 99-later

60E

65E

70E

Captured Front Planetary Bearing

60

60E

65E

70E

Koyo Bearing Kit

60

60E

65E

70E

3-4 Clutch Boost Spring & Retainer Kit

77747-01
SBK-G12

OE

8667424

60

Governor Gear Kit

702

60

Governor

729

60

Governor

730

60

Governor

731

60

60E

Rear Planetary Oil Deflector

60

60E

Rear Planetary Rebuild Kit

4 Pinion; parts also sold seperately

77731-08
77731-RK

65E

70E

Rear Planetary Rebuild Kit

5 Pinion; parts also sold seperately

77732-RK

60

60E

65E

70E

Rear Endplay Shim

.010" Thick, 10/bag

77406-10

60

60E

65E

70E

Front Endplay Shim

.015" Thick, 10/bag

77409-15

60

60E

65E

70E

Input Drum Reinforcement Kit

Includes sleeve & seal

60

60E

65E

70E

Reinforced Input Housing Kit

Reluctor 04-later

77733-04K

60

60E

65E

70E

Reinforced Input Housing & Shaft Kit

Non-Reluctor (4L60-E 9895)

77733-05K

Machining Required

Yes

77733-02K

Get your gearhead on www.sonnax.com


10

4L60/E

PERFORMANCE

Performance & Heavy Duty

TransmissionParts
Dont risk throwing products from different manufacturers into the same tranny
when theres no guarantee theyre all going to play nice. Installing Sonnax parts
designed to work together is the BEST and SAFEST way to upgrade a transmission.

Use these charts to get the most


out of your Sonnax 4L60-series rebuild!

Heavy Duty

Pickup Build

Option A

Option B

Line Pressure Booster Kit

See page 4

Performance Pack

HP-4L60E-01

SmartShell

77749-02K

SmartShell

77749-02K

Rear Stator Support Bushing

77002BT-01

Rear Stator Support Bushing

77002BT-01

4 Gear Super Hold Servo

77767K

4 Gear Super Hold Servo

77767K

Heavy Duty 2-3 Shift Valve

77754-41

Heavy Duty 2-3 Shift Valve

77754-41

th

Level 1

th

Performance Build

Option A

Option B

Line Pressure Booster Kit

See page 4

Performance Pack

HP-4L60E-01

SmartShell

77749-02K

SmartShell

77749-02K

Rear Stator Support Bushing

77002BT-01

Rear Stator Support Bushing

77002BT-01

4 Gear Super Hold Servo

77767K

th

Super Hold

Choose 2
Gear Servo
nd

77911-03K

Corvette Ratio 77701-04K

See pages 9 & 10 for more 4L60/E series


Sonnax parts IDEAL for everyday rebuilds
or performance/heavy duty applications!

Level 2

Level 3

Performance Build

Performance Build

Performance Pack

HP-4L60E-01

Performance Pack

HP-4L60E-01

SmartShell

77749-02K

SmartShell

77749-02K

Rear Stator Support Bushing

77002BT-01

Rear Stator Support Bushing

77002BT-01

Heavy Duty 2-3 Shift Valve

77754-41

Heavy Duty 2-3 Shift Valve

77754-41

4th Gear Super Hold Servo

77767K

4th Gear Super Hold Servo

77767K

2 Gear Corvette Ratio Servo

77701-04K

2 Gear Super Hold Servo

77911-03K

Input Drum Reinforcement Kit

77733-01K

Smart-Tech Input Housing

See page 6

Billet Forward Piston

77764-01

Billet Forward Piston

77764-01

nd

Choose
Wide Band

Red Band

77700-01

Kevlar Band

77700-01K

nd

Choose
Wide Band

Red Band

77700-01

Kevlar Band

77700-01K

*Includes rear stator support bushing.


4L60/E Performance & Heavy Duty Transmission Catalog Vol. 1
Sonnax Industries, Inc. 1 Automatic Drive P.O. Box 440 Bellows Falls, VT 05101-0440 USA
Contact us 8:30 a.m. to 5 p.m. ET (800) 843-2600 (802) 463-9722 fax (802) 463-4059 www.sonnax.com

2013 Sonnax Industries, Inc.